Adjustable plaster ring cover

ABSTRACT

A power distribution system has an electrical box configured to attach a power cable, a plaster ring releasably mounted to the box and one or more electrical devices installed into the ring. A pre-wired ground extends from a first end physically and electrically connected to a ground terminal on the electrical device. The plaster ring is movable between a closed position proximate the box and an open position distal the box. The pre-wired ground is configured as a lanyard so as to support the plaster ring as a wiring platform in the open position for connecting wires between the power cable and the electrical device or devices.

CROSS-REFERENCE TO RELATED APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet, or any correction thereto,are hereby incorporated by reference under 37 CFR 1.57.

INCORPORATION BY REFERENCE

Wiring modules and corresponding functional modules are described inU.S. Pat. No. 6,884,111 entitled Safety Module Electrical DistributionSystem, issued Apr. 26, 2005; U.S. Pat. No. 6,341,981 entitled SafetyElectrical Outlet And Switch System, issued Jan. 29, 2002; and U.S. Pat.No. 6,894,221 entitled Safety Outlet Module, issued May 17, 2005.Modular electrical devices, electrical boxes and adjustable mounts aredescribed in U.S. patent application Ser. No. 10/924,555 entitledUniversal Electrical Wiring Component, filed Aug. 24, 2004. A wiringsupport platform is described in U.S. patent application Ser. No.11/108,005 entitled Hinged Wiring Assembly, filed Apr. 16, 2005. All ofthe above-referenced patents and patent applications are herebyincorporated herein by reference.

BACKGROUND OF THE INVENTION

A power distribution system may comprise an electrical box, a plasterring and an electrical device, such as an outlet or switch. During aroughing phase of construction, electrical boxes with attached plasterrings are mounted to wall studs at predetermined locations. A journeymanelectrician routes power cables through building framing to theappropriate box. Then power cables are fed through openings in the rearor sides of the boxes and folded back inside. During a trim phase,electrical devices are mounted to the plaster rings.

SUMMARY OF THE INVENTION

Conventional electrical distribution systems consist of eitherprefabricated components customized for particular electricaldistribution points within a building or individual components that mustbe planned for, ordered, allocated to building locations and thenattached together and wired during installation at each electricaldistribution point. Further, it is impractical to test each wiredinstallation for conformance to construction standards.

A pre-wired power distribution system, in contrast, advantageouslycombines installation flexibility, convenience and verifiability. Acombination electrical box, plaster ring, one or more electrical devicesinstalled in the plaster ring and one or more pre-wired grounds betweenthe electrical box and the electrical device or devices provides for apre-tested ground path. In an embodiment, the electrical device is awiring module configured to accept any of various functional modules.The pre-wired ground also functions as a lanyard between the electricaldevice and the electrical box, allowing the plaster ring to be pivotedto, and supported in, an open position to provide hands-free connectionof power wires to the electrical device. This feature is particularlyuseful for wiring gang electrical boxes housing multiple electricaldevices. In an embodiment, a ground bus bar mounted to the electricalbox provides further flexibility by accommodating multiple grounds forpower cables routed to the electrical box. In this manner, an electricalbox, a plaster ring and wiring module or other electrical device ordevices may be manufactured, assembled, distributed and/or installed asa pre-wired power distribution component, by itself or in combinationwith an adjustable mount.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-B are perspective views of a pre-wired power distributionsystem in an open position and a closed position, respectively;

FIG. 2 is a perspective view of a pre-wired power distribution systemembodiment having a writing module with external push wire connectors;

FIG. 3 is a perspective view of a pre-wired power distribution systemembodiment having a wiring module with internal push wire connectors;

FIG. 4A is a front perspective view of an embodiment of a wiring modulewith internal push wire connectors;

FIG. 4B is a rear perspective view of the wiring module of FIG. 4A; and

FIG. 5 is a perspective view of a pre-wired power distribution systemembodiment having a box-mounted ground bus bar;

FIG. 6 is a front view of a modular integrated wiring system utilizingvarious embodiments of a universal electrical wiring component;

FIG. 7 is a front perspective exploded view of a universal electricalwiring component having modular electrical devices combined with anadjustable, modular mount;

FIG. 8 is a front perspective view of a floor bracket electrical wiringcomponent;

FIG. 9 is a front perspective view of a stud bracket electrical wiringcomponent;

FIG. 10 is a front perspective view of a box bracket electrical wiringcomponent;

FIG. 11 is a front perspective view of an extended box bracketelectrical wiring component;

FIG. 12 is an exploded perspective view of a junction box assembly;

FIG. 13 is an exploded perspective view of a floor bracket assembly;

FIG. 14 is an exploded perspective view of a stud bracket assembly;

FIG. 15 is an exploded perspective view of a box bracket assembly;

FIG. 16 is an exploded perspective view of an extended BOX bracketassembly;

FIG. 17 is an exploded perspective view of an adjustable plaster ring;

FIG. 18 is a perspective view of a junction box; and

FIGS. 19A-D are top, perspective, front and side views, respectively, ofa support arm.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1A-B illustrate a pre-wired power distribution system 100 havingan electrical box 120 configured to attach at least one power cable, anadjustable plaster ring 140, an electrical device 160 mounted to theplaster ring 140 and a ground lanyard 180 pre-wired between theelectrical device 160 and the electrical box 120. The electrical box 160can be any type known in the art.

In some embodiments, the electrical device 160 is a wiring module thatis configured to connect to a source of electrical power via a pluralityof cables (e.g., hot, neutral, and ground cables). The plurality ofcables (not shown) are fed through the electrical box 120 and connectedto a wiring portion of the wiring module, as disclosed herein. In someembodiments, once the wiring module is connected to power cables andfully installed within the electrical box 120, the wiring portion of thewiring module is substantially enclosed by the electrical box 120 andthe adjustable plaster ring 140, and is inaccessible to users. Thewiring module also includes a user-accessible portion that removablyaccepts a functional module (not shown) that provides a selectedelectrical power distribution function. For example, the functionalmodule may be an outlet receptacle or a switch. The user-accessibleportion of the wiring module includes shielded connectors, or sockets,that mate with the functional module. The shielded connectors helpreduce the risk of electrical shock to users when a functional module isnot installed in the wiring module. In FIG. 1B, the shielded connectorsare concealed by a protective cover 161 that protects the connectorsfrom foreign objects, for example, during a rough-in phase ofconstruction. The functional module can be installed without accessingthe wiring portion of the wiring module or the power cables.

In some embodiments, the electrical device 160 (e.g., a wiring module)is mounted to the adjustable plaster ring 140. The adjustable plasterring provides for an adjustable distance between the electrical device160 and the electrical box 120. For example, the adjustable plaster ringmay include adjusting screws that can be turned to increase or decreasethe distance between the electrical device 160 and the electrical box120. In this way, the depth of the electrical device 160 within a wallcan be adjusted to result in the desired fit with the wallboard.

One lanyard end 182 is connected to a box ground junction 122 andanother lanyard end 184 is connected to an electrical device terminal162. The plaster ring 140 can be releasably attached to the electricalbox 120. The plaster ring 140 is movable between an open position FIG.1A distal the electrical box 120 and a closed position FIG. 1B proximatethe electrical box 120. The plaster ring 140 can be releasably attachedto the electrical box 120 in the closed position. The ground lanyard 180provides a ground path from the electrical device 160 to the electricalbox and mechanically supports the plaster ring in the open position. Insome embodiments, however, the ground lanyard 180 does not necessarilysupport the plaster ring in the open position.

In an embodiment, the ground lanyard 180 is a ground wire connectedbetween a single point ground 222 (FIG. 2) on the electrical box 120 anda ground terminal 252 (FIG. 2) on the electrical device 160, asdescribed in further detail with respect to FIGS. 2-3, below. In anotherembodiment, the ground lanyard 180 includes multiple ground wiresconnected between a ground bus bar 450 (FIG. 4) mounted on a multi-gangelectrical box 420 (FIG. 4) and the ground terminals 462 (FIG. 4) ofmultiple electrical devices 460 (FIG. 4) mounted in a multi-gang plasterring 440 (FIG. 4), as described in further detail with respect to FIG.4, below. As described herein, the electrical devices 160 may be wiringmodules that are configured to accept various functional modules. Theelectrical box 120 is adapted to utilize various adjustable or fixedstud brackets, and the plaster ring 140 may be adjustable. These aspectsfacilitate the positioning of the mounted electrical devices during wallinstallation of the ground wire supporting wiring assembly 100. Withthis combination of features, a pre-wired power distribution systemprovides a broadly adaptable electrical system component.

The connections between the ground lanyard 180 and the electrical box120 can be formed using any type of connection known in the art. Forexample, a connection between the ground lanyard 180 and the electricalbox 120 or the electrical device 160 may comprise an electrical screwterminal or a push-in connector. In some embodiments, the electricalscrew terminal is treated with a threadlocker material once theconnection is made to improve the mechanical reliability of theconnection. The ground lanyard 180 can also be soldered or clamped tothe electrical box 120 or the electrical device 160. Advantageously, incases where the electrical device 160 is a wiring module, the connectionbetween the ground lanyard 180 and the electrical box 120 or theelectrical device 160 can be made substantially permanent because thewiring module need not be removed to replace an outlet receptacle,switch, or other similar functional module. In contrast, it wouldgenerally be undesirable to form a permanent ground connection between aconventional outlet receptacle or switch and an electrical box 120because doing so may prevent the replacement of the conventional outletreceptacle or switch. The fact that the connections between the groundlanyard 180 and the electrical device 160 or the electrical box 120 canbe made substantially permanent can also allow the connections to bemade stronger (allowing the ground lanyard to support the weight of theelectrical device 160 and adjustable plaster ring 140, as describedherein) and more reliable, both from a mechanical and an electricalstandpoint.

The pre-wired ground lanyard 180 can be advantageously tested at themanufacturer. In an embodiment, the ground lanyard 180 is subjected to amechanical pull test and an electrical continuity test. In a particularembodiment, the pull-test has at least a 20 lb. force. The mechanicalpull test and the electrical continuity test would otherwise be toocumbersome to perform on ground connections installed by an electricianat a worksite. However, since the ground connection between theelectrical device 160 and the electrical box 120 is installed at themanufacturer, these tests can be performed more efficiently than can bedone at a worksite. Moreover, these tests can be performed usingequipment that is too expensive or bulky to use at a worksite where theground connection might otherwise be installed. In some embodiments,however, the ground lanyard 180 is not pre-wired but is insteadconfigured to be connected upon installation of the electrical device160 within the electrical box 120.

Since the ground connection between the electrical device 160 and theelectrical box 120 acts as a pull-tested lanyard 180, the plaster ring140 can be supported in an open position (FIG. 1A) by the ground lanyard180, advantageously allowing an electrician hands-free access to one ormore electrical devices 160 so as to wire these devices to power cablesrouted to the electrical box 120. Upon wiring completion, the plasterring 140 is moved to a closed position (FIG. 1B) and secured to theelectrical box 120. Multiple electrical devices 160 can be pre-attachedto the plaster ring 140 because doing so does not block access to theelectrical box 120 or impede the wiring process. Further, the use of aground bus bar as the electrical box ground junction 184 advantageouslyallows the ground wiring of one or more power cables to the bus barwithout resorting to ad hoc pigtail junctions or the use of theelectrical device connectors.

FIG. 2 illustrates a pre-wired power distribution system embodiment 200having a wiring module 260 pre-wired with push-wire connectors 250. Aground wire 280 extends between the wiring module 260 and an electricalbox 120. In some embodiments, the ground wire 280 includes a push-wireconnector at some point along its length to be connected to a groundcable fed into the electrical box 120 along with other powerdistribution cables. The ground wire 280 has a first end 282 attached toa ground push-wire connector 252 and a second end 284 secured to aground attachment point 222 in the interior of the electrical box 120.In some embodiments, the ground attachment point 222 is a screwterminal. The push-wire connectors 250 are connected to internal crimpwires of the wiring module 260 and adapted to accept power and groundwires from cables (not shown) routed to the electrical box 120. Anelectrician can easily and quickly attach the power wires to theappropriate push wire connectors 250 while the plaster ring 140 issupported by the ground wire 280.

FIG. 3 illustrates another pre-wired power distribution systemembodiment 300 having a wiring module 360 with internal push-wireconnectors 350. A ground wire 280 extends between the wiring module 360and an electrical box 120. The ground wire 280 has a first end 282attached to a ground push-wire connector 352 and a second end 284secured to a ground attachment point 222 in the interior of theelectrical box 120. The push-wire connectors 350 are adapted to acceptpower and ground wires from cables (not shown) routed to the electricalbox 120.

FIG. 4A is a front perspective view of an embodiment of a wiring module460 having internal push-wire connectors 407. The wiring module 460 hasa mounting bracket 406 with an aperture 401 to mount the wiring module460 to an adjustable plaster ring (e.g., 140) and an aperture 402 toattach a protective cover (e.g., 161) to the wiring module 460. Thewiring module 460 also includes shielded connectors 403 for receiving afunctional module (e.g., an outlet receptacle functional module or aswitch functional module).

FIG. 4B is a rear perspective view of the wiring module 460. The wiringmodule 460 includes a screw terminal ground lanyard connection point452. In other embodiments, the ground lanyard connection point is, forexample, an internal push-wire connector, a soldered joint, or a clampedjoint. The wiring module 460 also includes internal push-wire connectors407 for receiving power cables (e.g., hot, neutral, and ground powercables) routed to an electrical box (e.g., 120). The internal push-wireconnectors 407 can also be used for creating a ground connection betweenthe wiring module 460 and an electrical box (e.g., 120). For example,the wiring module 460 could be mechanically and electrically coupled toan electrical box via a pre-wired ground lanyard (e.g., 180). Theinternal push-wire connectors 407 can be, for example, any type ofpush-in connector housed wholly or partially within the wiring module460 for receiving power cables. In some embodiments, the internalpush-wire connectors 407 are stab-in connectors. The wiring module 460also includes a tab 405 that covers screw terminals that are inelectrical contact with individual ones of the internal push-wireconnectors 407. The screw terminals can be used as an alternative to theinternal push-wire connectors 407 if desired.

The internal push-wire connectors 407 are particularly advantageous insituations where space within the electrical box 160 is limited or inany other setting where it is desirable to conserve space within theelectrical box 160. This may be true, for example, in relatively shallowwalls (e.g., walls measuring less than about 3″ from the outside edge ofa wall stud to the back wall). The internal push-wire connectors 407conserve space within the electrical box 160 (or allow for the usage ofa shallower depth electrical box 160) because they do not include alength of wire between the wiring module and a connector as is the casefor the embodiment illustrated in FIG. 2 having external push-wireconnectors 250. While such external push-wire connectors 250 aredesirable under some circumstances, the internal push-wire connectors ofFIGS. 3-4 can result in space and cost savings due to the elimination ofwire joining the connectors (e.g., 250) to the wiring module (e.g.,260). It should be understood that the wiring module 460 with internalpush-wire connectors can be used with or without a pre-wired groundlanyard (e.g., 180).

FIG. 5 illustrates a pre-wired power distribution system embodiment 500having a 3-gang electrical box 520, a 3-gang adjustable plaster ring540, a ground bus bar 550 mounted directly to the electrical box 520,three wiring modules 560 attached to the plaster ring 540 and a multiplewire ground lanyard 580. The ground lanyard 580 extends between the busbar 550 and ground terminals 562 on each of the wiring modules 560. Thebus bar 550 is configured to accept additional ground wires from powercables routed to and from the electrical box 520. As such, the groundlanyard 580 supports the plaster ring 540 in the open position shown,providing a wiring platform for the electrician to wire all three wiringmodules 560 as a unit without having to handle and hold each of thewiring modules individually during the wiring process.

Advantageously, the bus bar 550 is configured to allow the attachment ofmultiple ground wires 580 so as to provide ground connections for notonly wiring modules, but also power cables routed in and out of theelectrical box 520. The bus bar 550 has a plurality of sections 552 andindividual terminals 551 within each section. In an embodiment, there isone section 552 corresponding to each of the wiring modules 560 andmultiple terminals 551 in each section. Each of the sections can be inelectrical contact or electrically isolated. In this manner, groundwiring capacity increases with the size and electrical device mountingcapacity of the electrical box 520. Each terminal 551 is configured toaccept a ground wire 580 from either a wiring module 560 or an attachedpower cable. In a 3-gang embodiment, the bus bar 550 has three sectionscorresponding to three wiring modules, and each section has fourterminals configured to accept up to four ground wires, though othernumbers of sections and terminals are also possible. The bus bar 550advantageously eliminates the need for pigtail ground connections or theequivalent use of electrical device terminals. The bus bar 550 can beconfigured for use with external push wire connector wiring modules 260(FIG. 2), internal push wire connector wiring modules 360 (FIG. 3) orany electrical devices having push-wire, screw terminal or similar wireconnectors.

Although described and illustrated herein with respect to 1- and 3-gangembodiments, a pre-wired power distribution system can be configured forany number of electrical devices, including 2-gang, 4-gang, and othermany-gang embodiments. A pre-wired power distribution system has beendisclosed in detail in connection with various embodiments. Theseembodiments are disclosed by way of examples only and are not to limitthe scope of the claims that follow. One of ordinary skill in art willappreciate many variations and modifications.

FIG. 6 illustrates a modular integrated wiring system 600 utilizinguniversal electrical wiring component embodiments 800-1100. A floorbracket component 800, a stud bracket component 900, a box bracketcomponent 1000 and an extended box bracket 1100 are included, providingadaptability for different electrical power distribution designs. Eachwiring component 800-1100 provides mounting flexibility by adjusting tovarious wall dimensions, stud configurations, and electricaldistribution point locations. Specifically, each component 800-1100 hasan adjustable depth into the wall, guaranteeing a flush finish with thewall surface at every electrical distribution point. In addition, thefloor bracket component 800 provides an adjustable height. The studbracket component 900 can be positioned at any height and provides anadjustable distance between studs. The box bracket component 1000 can bepositioned at any height, and the extended box bracket component 1100can be positioned at any height and at various locations between studs.Further, each wiring component 800-1100 accommodates a variety offunctional modules, including various outlets, switches, GFCI devices,and motion detectors to name few. Advantageously, the color of thefunctional modules and even some functionality can be readily changed atanytime without rewiring, as described below. The resulting modularintegrated wiring system 600 has the labor saving advantages ofprefabrication with the design and installation flexibility ofindividually configured and wired components.

A universal electrical wiring component combining modular electricaldevices and an adjustable, modular mount is described with respect toFIG. 7, below. A floor bracket component 800 is described in furtherdetail with respect to FIG. 8, below. A stud bracket component 900 isdescribed in further detail with respect to FIG. 9, below. A box bracketcomponent 900 is described in further detail with respect to FIG. 9,below, and an extended box bracket component 1100 is described infurther detail with respect to FIG. 11, below. Adjustable mounts aredescribed in detail with respect to FIGS. 12-16, below.

FIG. 7 further illustrates a universal electrical wiring component 700having an adjustable mount 705 combined with a wiring module 701. Theadjustable mount 705 includes a bracket 707 and a box assembly 1200. Thebracket 707 can be, for example, a vertically adjustable floor bracket1300 (FIG. 13), a horizontally adjustable stud bracket 1400 (FIG. 14), abox bracket 1500 (FIG. 15), or an extended box bracket 1600 (FIG. 16).The box assembly 1200 is mounted to the bracket 707 and the wiringmodule 701 is mounted in the box assembly 1200. The wiring module 701may be a regular wiring module 710 or a GFCI wiring module 720. Theadjustable mount 705 is configured to position the wiring module 701 atany of various locations within a building wall. The wiring module 701is configured to connect to a source of electrical power and toremovably accept a functional module 703. Advantageously, thecombination of adjustable mount and wiring module form a universalelectrical wiring component that can implement a variety of electricaldistribution points of an electrical system. For example, a universalelectrical wiring component can accept various outlet modules 750-760and can be adjusted to implement a wall outlet. As another example, auniversal electrical wiring component can accept various switch modules740 and can be adjusted to implement a switch outlet. A universalelectrical wiring component 200 may be, for example, a floor bracketcomponent 800 (FIG. 8), a stud bracket component 900 (FIG. 9), a boxbracket component 1000 (FIG. 10) or an extended box bracket component1100 (FIG. 11). A cover 704 may be used to protect a wiring module 701from damage prior to functional module installation.

FIG. 8 illustrates a floor bracket component 800 having a wiring module701 and an adjustable mount comprising a box assembly 1200 and a floorbracket 1300. In this embodiment, the floor bracket 1300 provides thewiring module 701 an adjustable height from the floor and the boxassembly 1200 provides the wiring module 701 an adjustable distance fromthe box assembly 1200 for a flush position with a wall surface.

FIG. 9 illustrates a stud bracket component 900 having a wiring module701 and an adjustable mount comprising a box assembly 1200 and a studbracket 1400. In this embodiment, the stud bracket 1400 provides thewiring module 701 an adjustable distance between studs and the boxassembly 1200 provides the wiring module 701 an adjustable distance fromthe box assembly 1200 for a flush position with a wall surface.

FIG. 10 illustrates a box bracket component 1000 having a wiring module701 and an adjustable mount comprising a box assembly 1200 and a boxbracket 1500. In this embodiment, the box bracket 1500 allowspositioning of the wiring module 701 along a vertical stud. Also, thebox assembly 1200 provides the wiring module 701 an adjustable distancefrom the box assembly 1200 for a flush position with a wall surface.

FIG. 11 illustrates an extended box bracket component 1100 having awiring module 701 and an adjustable mount comprising a box assembly 1200and an extended box bracket 1600. In this embodiment, the extended boxbracket 1600 allows vertical positioning of the wiring module 701 alonga stud and horizontal positioning between studs. Also, the box assembly1200 provides the wiring module 701 an adjustable distance from the boxassembly 1200 for a flush position with a wall surface.

FIG. 12 illustrates a box assembly 1200 having a junction box 1800, anadjustable plaster ring 1700 and a support arm 1900. The plaster ring1700 removably attaches to the junction box 1800 and a wiring module 701(FIG. 7) attaches to the plaster ring 1700. The plaster ring providesthe wiring module 701 (FIG. 7) with an adjustable distance from thejunction box 1800, as described in detail with respect to FIG. 17. Thejunction box 1800 advantageously has an attached ground wire that can bequickly connected to a wiring module 701 (FIG. 7). The plaster ring 1700has slotted fastener apertures so that the plaster ring 1700 along withan attached wiring module can be removed from, and reattached to, thejunction box 1800 by merely loosening and tightening, respectively, thefasteners. The support arm 1900 attaches to the back of the junction boxto provide support against an inside wall surface, as described infurther detail with respect to FIGS. 19A-D, below.

FIG. 13 illustrates a floor bracket 1300 having an open front 1301 andruled sides 1310. The floor bracket 1300 has tabs 1320 for attaching thebracket 1300 to one or both of a floor joist or a wall stud. Sidegrooves 1330 allow fasteners to attach the junction box 1800 at anadjustable height from the floor. Conduit supports 1340 are adapted forattachment to conduits running to the junction box 1800. The plasterring 1700 is attached to the box 1800 through the open front 1301 sothat the plaster ring 1700 can be removed from the box 1800 withoutremoving the box 1800 from the bracket 1300.

FIG. 14 illustrates a stud bracket 1400 having a horizontal bar 1401 andends 1403. The ends 1403 are folded perpendicularly to the bar 1401 andadapted to secure the bracket 1400 horizontally between wall studs. Thebar 1401 has grooves 1410 and a slot 1420 that extend horizontally toproximate both ends 1403 of the bracket 1400. The grooves 1410 areadapted to slideably retain corresponding box tongues 1812 (FIG. 18).The slot 1420 is centered between the grooves 1410 and accommodates afastener that secures the junction box 1800 to the bracket 1400 whileallowing the box to slideably adjust in position along the bar 1401. Theplaster ring 1700 is attached to the box 1800 and can be removed fromthe box 1800 without removing the box 1800 from the bracket 1400.

FIG. 15 illustrates a box bracket 1500 having a stud mounting face 1501and a box mounting face 1503. The stud mounting face 1501 is disposedperpendicular to the box mounting face 1503 and is adapted to fasten toa wall stud. Either side of the junction box 1800 attaches to the boxmounting face 1503. The box mounting face 1503 has a keyhole slots 1511allowing the junction box 1800 to fasten and unfasten to the bracket1500 without removing the fasteners 1520. The stud mounting face 1501has a plurality of mounting holes 1610 to accommodate fasteners thatallow the junction box 1800 to be positioned along a stud.

FIG. 16 illustrates an extended box bracket 1600 having an extended studmounting face 1601 and a box mounting face 1603. The box mounting face1603 is disposed perpendicular to the extended stud mounting face 1601and is adapted to fasten to the junction box 1800. The extended studmounting face 1601 is adapted to fasten to a wall stud. The extendedstud mounting face 1601 has a plurality of mounting holes 1610 spacedalong the length of the bracket 1600 to accommodate fasteners thatallows the junction box 1800 to be position vertically along a stud andhorizontally between studs.

FIG. 17 further illustrates an adjustable plaster ring 1700 having abase ring 1710, an insert ring 1720 and adjusting screws 1730. Theinsert ring 1720 is slideably retained by the base ring 1710 and securedto the base ring 1710 by the adjusting screws 1730. The insert ring 1720is adapted to mount a wiring module and to adjust the wiring moduleposition relative to the base ring 1710 in response to turning of thescrews 1730. The base ring 1710 has keyhole slots 1714 adapted toaccommodate fasteners that attach the plaster ring 1700 to a junctionbox. The keyhole slot 1714 allows the plaster ring 1700 to fasten andunfasten to the junction box without removing the fasteners.

FIG. 18 further illustrates a junction box 1800 having a ground wire1810, a tongue 1812 and knockouts 1814. The ground wire 1810, beingpre-wired to the box, advantageously saves a fabrication step on the jobsite. Further, the ground wire 1810 is configured to insert into apush-wire connector on a pre-wired wiring module, providing a plug-infunction module with a path to ground. The tongue 1812 stabilizes thebox within a groove on a stud bracket, if used. The knockouts 1814provide attachment points for power cable conduits.

FIGS. 19A-D further illustrate a support arm 1900 adapted to attach to aback face of the junction box 1800 (FIG. 18) and provide support againstan inside wall surface. In particular, the support arm 1900 has anattachment section 1901 and a support section 1902 extending generallyperpendicularly from one end of the attachment section 1901. Theattachment section is generally planar having an inside face 1904 thatis disposed against the junction box 1800 and an opposite outside face1905 that is disposed distal the junction box 1800. The support section1902 has a support face 1907 that is disposed against an inside wallsurface. The attachment section 1901 has an adjustment slot 1910, afastener hole 1920, and a plurality of bending slots 1930 distributedalong and extending perpendicularly across the adjustment slot 1910. Theattachment section 1901 is configured to bend along one of the bendingslots 1930 so as to provide a variable length support extendinggenerally normal to the junction box back face. The support arm 1900 isheld to the box 1800 with a fastener that is slideable along theadjustment slot 1910, providing an adjustable support arm position.

A universal electrical wiring component has been disclosed in detail inconnection with various embodiments. These embodiments are disclosed byway of examples only and are not to limit the scope of the claims thatfollow. One of ordinary skill in the art will appreciate many variationsand modifications.

1. An apparatus for use in an electrical distribution system, theapparatus comprising: an electrical box configured to accept at leastone electrical power cable; a plaster ring configured to be mounted tothe electrical box, wherein the plaster ring has an open front face thatprovides access to an interior of the electrical box; an electricalwiring module within the interior of the electrical box, the electricalwiring module including one or more conductors that couple theelectrical wiring module to one or more of the power cables, theelectrical wiring module further including one or more connectors toelectrically couple to a functional module; a first cover configured toprotect one of more of the connectors on the wiring module; and a secondcover configured to substantially cover the open front face of theplaster ring.
 2. The apparatus of claim 1, wherein at least one of thewiring module conductors is electrically connected to the electricalbox.
 3. The apparatus of claim 2, wherein the wiring module conductorsare configured with wire connectors.
 4. The apparatus of claim 1,wherein the second cover is attached to the plaster ring with one ormore screws.
 5. The apparatus of claim 4, wherein the second coverincludes a plate.
 6. The apparatus of claim 1, where one of the firstand second covers is flexible.
 7. The apparatus of claim 1, wherein thefirst cover is flexible and the second cover is hard.
 8. The apparatusof claim 1, further comprising mounting brackets configured to mount theapparatus to ensure the center of the functional module when coupledwith the wiring module will be between 12 and 20 inches from the floor.9. The apparatus of claim 1, further comprising mounting bracketsconfigured to mount the apparatus to a construction stud allowing thebox to be moved to a variety of positions vertically on the stud or tomove the apparatus horizontally between two studs on a wall, ceiling orfloor.
 10. The apparatus of claim 1, wherein the electrical box isconfigured to be mounted to a hard surface or within a hard surface. 11.The apparatus of claim 1, wherein the first cover must be removed toelectrically couple a functional module with the wiring module.
 12. Theapparatus of claim 1, wherein the second cover protects must be removedto electrically connect the functional module.
 13. The apparatus ofclaim 1, wherein the second cover protects the wiring module, the firstcover and one or more of the conductors.
 14. The apparatus of claim 1,further comprising a functional module.
 15. An electrical apparatusmanufacturing method comprising: placing one or more electrical wiringmodules within an interior of an electrical box, each electrical wiringmodule including one or more fixed conductors that couple the electricalwiring module to one or more power cables, the electrical wiring modulefurther including one or more connectors disposed thereon that areconfigured to electrically couple to a functional module; mounting aplaster ring to the electrical box wherein the plaster ring includes anopen front face that provides access to the interior of the electricalbox; and mounting a hard protective cover to the plaster ring.
 16. Theelectrical apparatus manufacturing method of claim 15, wherein theplaster ring is removeably mounted with two or more screws.
 17. Theelectrical wiring method of claim 9, wherein the hard protective coveris attached with two or more screws.
 18. The electrical apparatusmanufacturing method of claim 15, further comprising: respectivelymounting a functional module to each wiring module.
 19. The electricalapparatus manufacturing method of claim 9, wherein at least one of thewiring modules fixed conductors is connected to the electrical box witha screw or wire connector.
 20. The electrical apparatus manufacturingmethod of claim 9, wherein at least one conductor from each of thewiring modules is connected to the electrical box via a wire connectoror screw.